Wearable sensors in Industry 4.0: Preventing work-related musculoskeletal disorders

Work-related musculoskeletal disorders (WMSDs) are a global health and economic challenge, particularly in industrialized nations, accounting for up to 2 % of GDP losses due to disability and productivity reduction. Wearable sensors, driven by Industry 4.0 advancements, offer transformative potential for real-time ergonomic assessment and injury prevention. This systematic review analyzes 40 peer-reviewed studies (2013–2024) to evaluate the application of inertial measurement units (IMUs), electromyography (EMG) sensors, and pressure sensors in mitigating WMSD risks. Findings demonstrate that wearable technologies enhance workplace safety through real-time feedback, reducing ergonomic risks and improving productivity. Despite promising advancements, challenges such as scalability, user comfort, and data privacy persist. This review emphasizes the need for standardized protocols, ethical frameworks, and deeper integration with machine learning to optimize sensor accuracy and usability. Future research directions include advancing AI-driven predictive ergonomics, addressing privacy concerns, and improving sensor design for widespread industrial adoption. This study provides actionable insights to bridge the gap between academic research and practical deployment in diverse industrial settings.